SAE AS5780 Turbine Oil Specification

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Dortha Stone
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2 Overview Commercial Turbine Engine Lubricants Current Next Specifications MIL-PRF SAE AS5780 Grades STD, C/I, HTS SPC, HPC Viscosities 5 cst 5 cst Coking, O-ring compatibility, hightemperature, long duration, etc. Performance Data Insufficient Data quality US NAVY Independent lab verification Change Control US NAVY Type Certificate Holder Support US NAVY NAVY, FAA, EASA, OEMs, Oil Comps Industry moves towards HPC, for high-temperature use, and low coking. All Rights Reserved 2

3 Executive Summary SAE AS5780 specification FAA and EASA endorsement Wide range of test data on lubricants Two completely New Turbine Lubricants were approved in 2007 Reduced Coking High Temperature Capability Type Certificate Holder responsibility Engines stay on-wing for 20,000 flight hours or 6 years, Those numbers will be going to 40,000 hours and 12 years. All Rights Reserved 3

5 AS5780 specification Background Reasons for AS5780 Additional tests: Several OEMs have additional test requirements over MIL-PRF Coking has caused IFSD and UER of RR engines O-Ring deterioration with HTS lubricant use Others: conductivity, specific heat, load carrying capability Quality. Traceability. Change control of existing products. US Navy resources directed to focus on DoD activities. Only AS5780 meets FAA and EASA requirements All Rights Reserved 5

7 Elastomer Compatibility Air Oil Elastomers Tested: Generic name Example Specification Fluorocarbon (amine cure) Viton A AMS 7276 LCS Fluorocarbon (peroxide cure) Viton GLT, GFLT AMS Nitrile rubber MIL-P (Fluoro) Silicone Perfluoroelastomer Kalrez, Chemrez AMS 7257 Fluorocarbon AFLAS AMS 7255 O-ring test All Rights Reserved 7

8 AS5780 specification Background FAA, EASA perspective: Lubricant is a Critical Part because all engines on one airplane may receive the same lubricant from the same batch/container. Must have Quality Control of oil manufacturing process. Must have Change Control of that process. Must have Traceability of oil and oil components. Type Certificate Holder is responsible for the turbine oil. Type Certificate Holders for GE: CF34, CFM56, CF6, GEnx, GE90. Analogy, Toyota: Corolla, Camry, Prius, Sienna, Tundra, Tacoma All Rights Reserved 8

9 Quality Control Specifications for components. Written procedures for processes, including equipment. Procedures for equipment maintenance and calibration. Personnel training procedures and requirements. Procedures for inspection. Procedures for disposition of out-of-spec materials. Procedures for identification, storage and handling. Procedures for shelf life. Procedures for Quality Audits. All Rights Reserved 9

10 Change Control No significant changes can be made to the product or manufacturing process without prior written approval. Suppliers of base stocks and additives must sign a document confirming their understanding of the above rule. Those documents must be kept on file and renewed from time to time. No changes to be made without prior written approval. All Rights Reserved 10

11 Traceability A container of oil on the flight line must be traceable to a lubricant batch number. The lubricant batch number must be traceable to batch numbers of lubricant base oil and batch numbers of each of the components. The sales points of a lubricant batch number must be traceable. The sales points of lubricant batches containing a specific batch of base oil or additive must be traceable. The above information enables a quick determination to be made of which planes may be affected when suspicions are raised about a specific batch of lubricant, or base oil, or additive. It is desirable to quickly minimize the number of aircraft that may be affected. All Rights Reserved 11

12 Data for Traceability an example Process Operator Batch 1 Master Melt A 2 Blade Casting B Machining C Hole Drilling D Bond Coating E Top Coating F Suspect Part 3 Serial number, process, operator, machine, batch, day, are recorded for every step in the manufacturing process. All Rights Reserved 12

13 AS5780 specification Status SAE AS5780 specification was issued October Oil companies participating: BP, ExxonMobil, Shell, Anderol, Hatco, Nyco. OEM and User Groups participating: Airbus, Boeing, British MoD, Honeywell, GE, Pratt & Whitney, Rolls-Royce, Snecma, US Navy. Initial Qualified Products List was issued in June, Seven lubricants have been approved. Change Notifications for two lubricants simultaneously approved. FAA approved QPG procedures. 2 New HPC oils were developed. All Rights Reserved 13

15 Organization SAE has a commercial arm called Performance Review Institute (PRI) PRI receives Applications with proprietary composition and performance information from oil companies for AS5780 inclusion Governing body is the Qualified Products Group (QPG) QPG Members / Member Companies have signed a PIA with PRI Rep# Org# Organization Representative Position 1 1 Airbus Williams, Alun 2 2 Boeing Parr, Mike 3 2 Boeing Ray, Jean Chairman 4 3 British MoD Tucker, Jerry 5 4 General Electric Bruce, Robert Past Chairm 6 5 Hamilton Sundstrand Baker, Ken 7 6 Honeywell Fontana, Jim Secretary 8 7 Pratt & Whitney Spires, Larry 9 8 Rolls Royce Blackwell, Alan 10 8 Rolls Royce Bullock, Stuart 11 8 Rolls Royce Schwerin, Jennifer 12 8 Rolls Royce Shepherd, Tim Vice Chairm 13 9 Snecma Gauthier, Gerard US Navy Hille, Eric US Navy McDonnell, Jim US Navy Mearns, Doug US Navy Meza, Oscar All Rights Reserved 15

16 AS5780 Future Developments Engines will continue to run hotter because of the fuel efficiency benefits. High temperature HPC oils will supersede standard oils. Turbine lubricant business is a relatively small business. A next generation of lubricant is probably not going to be backwards compatible, so the market will be very small and developing slowly. All Rights Reserved 16

17 g Summary SAE AS5780 was issued. FAA and EASA endorse AS5780. Qualified Products List (QPL) issued. Additional data is available on all AS5780 lubricants. New High Performance Capability (HPC) lubricants were developed. Specification: QPL: All Rights Reserved 17

19 Additional Tests Requirements with limits Deposition Properties: ERDCO Bearing HLPS Dynamic Coking Report Items Acid assay, Mole % FED-STD C ASTM D341 Viscosity Index ASTM D2270 Pressure Viscosity coefficient Wedeven/rolling ball Density ASTM D4052 Specific Heat ASTM D2766 or E1269 Not auto-ignition All Rights Reserved 19

20 Additional Tests (continued Report Items) Thermal Conductivity Holometrix Electrical Conductivity ASTM D2624 Elastomer Compatibility 1800 hr Snecma Hydrolytic Stability Def Stan Vapor Phase Coking SAE ARP5921 High temperature Deposit Alcor HTDT Severe Wear SAE AIR4978 Mild Wear SAE AIR4978 Thermal Aging 550 hrs Turbomeca 150C and 180C: Anti-oxidant, Density, Viscosity, Acidity, Flash Point Thermal Aging 72 hours Turbomeca 225C: Acidity, Flash Point Particulate Generation P&W All Rights Reserved 20

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